From digital twin to completed control panel in record time

(See Eplan at Machine Building North, 10 April 2025, on stand 96)

So, while order books may be full, actually fulfilling those orders, within tight timescales, is extremely stressful.

Fortunately, there is a simple solution - one that, in the longer term, will also help control panel manufacturers grow their business by increasing both their productivity and output.

If you are a control panel manufacturer, then by employing Eplan ECAD software and automation equipment from Rittal you can unlock significant efficiency improvements. Your teams will achieve far more within tighter time limits, at lower cost, and with fewer mistakes.

Rittal's automation equipment can be operated by more junior/less experienced team members, which strips away the repetitive manual processes within the panel build process such as drilling patterns, crimping cables and wiring; while delivering error-free outcomes.

This means that you can free up your skilled electrical engineers to support other, more strategic areas of client support and business development.

3D models, assistance applications and automation

Eplan software enables your electrical engineers to effortless create digital 3D models of each control panel layout. They can also generate manufacturing drawings and cutting lists for cable ducts, use 3D routing to determine cable lengths, label components and accurately place cables and components within the models.

All this data can then be exported as the technical specifications and the blueprint for automated production equipment to manufacture the panels - for example drill mounting plates, or accurately cut to length and crimp cables.

Because the process is entirely automated, errors are reduced, production times are speeded up and customer satisfaction will inevitably increase. What's more, by automating your production, you will create time and space for the business to take on more contracts, as well as increasing your profitability and competitiveness.

Review your operational efficiency

Creating online records also gives full transparency across your operative procedures and production methodologies, allowing you the opportunity to review these and ensure that they are as efficient as possible.

There are, of course, huge differences in shopfloor production techniques and performance; much depends on your customer type, your product range, how you like working, and your company strategy. However, when it comes to offering guidance on best operative practice on the shopfloor, here are a few useful pointers:

A) Team collaboration to ensure everyone buys into a solution and understand the value changes might bring

B) Ensuring your engineers fully appreciate what the shopfloor team needs in terms of good 3D drawing or wiring lists. This is also in the interest of the client. By liaising closely with engineering, the shopfloor team can speed up project turnaround.

C) Separate the process steps into designated workspaces, overseen by dedicated employees. This not only optimises output, it reduces inventory and lowers logistics costs. It also makes you more flexible and adaptable to changing business needs.

D) Arrange the production space logically, following the steps in the production process, allowing the product to be easily moved along each step.

E) Clean up the workplace at the end of the workday to organise and optimise workplace efficiency.

F) Use messaging boards or signage to ensure everyone knows where each product is in the workshop

G) Improve ergonomics and try and eliminate heavy lifting where possible.

H) Remove printers. Automation requires the entire flow of information - from design engineering to delivery and service - to be digital. If your company or department serves external clients, this may mean that you agree on a standardisation for each client. Or you may consider outsourcing the mechanical operations to your panel supplier.

I) Lower inventory stocks by planning production and coordinating with your suppliers to deliver goods only as and when they are required.

By sourcing your design software and the production equipment from compatible suppliers, such as sister companies Rittal and Eplan, you can be sure of complete compatibility and seamless data transfer between the electrical engineering team and your shopfloor.

But if you have manufacturing machines from other suppliers, Eplan can also export the data to their machines.

Automated panel production stages

1. Simply set the mounting plate. The manufacturing system, such as the Rittal Perforex machine, takes the data from the 3D model and automatically drills holes and mills threads as well as cutting any notches in the panel. There is no longer any need for error-prone manual data entries or hand-drilling.

2. The Rittal Wire Terminal will automatically cut wires to length based on Eplan data, as well as labelling, crimping and bundling cables. This can run in parallel to the cabinet modifications, based on the virtual prototype of the control panel created in Eplan. This will reduce cabling waste and speeds up production.

3. When it comes to assembly, technicians are guided by instructions from Eplan on a tablet or monitor, which takes them through the manual assembly and wiring of a control panel using step-by-step instructions. Several team members can work on the same or multiple control panels, even if they have very little prior experience. The status is updated within the software and can be viewed on a centralised dashboard for progress updates.

4. Up-to-date maintenance and servicing instructions, as well as up-to-date machine and plant system documentation, are available online on selective Rittal control panels via QR code, thereby reducing the amount of paperwork required by the client.

By leveraging the power of Eplan ECAD software and Rittal automation equipment, control panel manufacturers can transform their production processes and stay ahead of the mounting challenges facing the industry. From alleviating workforce shortages to streamlining workflows and increasing production capacity, these integrated solutions provide a robust pathway to higher efficiency, faster delivery times, and fewer errors.

As the demand for customised control panels continues to rise, investing in digital twin technology and automated production processes will position your business for long-term success. By adopting these cutting-edge tools today, you'll not only navigate the current storm but emerge as an industry leader ready to shape the future of panel manufacturing.